An intelligent supervision system for geopolymers production

Abstract

The present invention discloses an intelligent monitoring system for geopolymer production, which belongs to the technical field of geopolymer product quality detection. The present invention can accurately obtain the length characterization parameters, inner and outer arc surface accuracy characterization parameters, and width characterization parameters of refractory bricks; using the length between the center points of the corresponding detection frames as the length characterization parameter of the refractory brick, it can accurately and conveniently determine whether the length of the refractory brick is within the error range; and through the setting of the positioning circular plate and the combination of image recognition technology, it can accurately detect the inner and outer arc surface accuracy characterization parameters of the current refractory brick, and then accurately and conveniently determine whether the inner and outer arc surface accuracy of the refractory brick is within the error range; it also cleverly obtains the width characterization parameters of the current refractory brick based on the intermediate parameters obtained by the inner and outer arc surface detection module, and then accurately and conveniently determines whether the width of the refractory brick is within the error range.

Description

Technical Field

[0001] The present invention relates to the technical field of geopolymer product quality detection, and in particular to an intelligent monitoring system for geopolymer production. Background Art

[0002] Geopolymers offer a wide range of products, categorized by application into construction geopolymers, road geopolymers, and special-purpose geopolymers. Construction geopolymers, such as geopolymer cement, geopolymer concrete, and geopolymer refractory bricks, are used in the construction and maintenance of buildings; road geopolymers, such as geopolymer grouting materials and geopolymer adhesives, are used for paving and repairing roads; and special-purpose geopolymers, such as those used in electric furnace and reactor insulators, composite materials, and decorative products.

[0003] Geopolymer refractory brick is a kind of refractory brick made of geopolymer material. Geopolymer refractory brick has a wide range of application prospects in the construction and industrial fields due to its excellent fire resistance and multiple functional properties:

[0004] Geopolymer refractory bricks, with their excellent adhesion and plasticity, are more suitable than cement for the production of building blocks such as standard bricks, building blocks, and paving slabs. They can also be used to prepare grouting materials for filling underground caverns and mine goafs. Geopolymer refractory bricks can withstand high temperatures and are therefore suitable for the construction of various furnaces and hearths that must withstand high temperatures, such as incinerators, blast furnaces, glass kilns, and other industrial structures in steel manufacturing. These structures require stability and durability under high temperatures, and geopolymer refractory bricks are the ideal material to meet these requirements.

[0005] In high-temperature furnace masonry projects, which require high precision, the dimensional accuracy of geopolymer refractory bricks must be controlled within a set range. Accurately detecting the dimensional errors of geopolymer refractory bricks during production is an urgent problem. To address this issue, an intelligent monitoring system for geopolymer production is proposed. Summary of the Invention

[0006] The technical problem to be solved by the present invention is how to accurately detect the dimensional errors of geopolymer refractory bricks during the production process, and provides an intelligent monitoring system for geopolymer production.

[0007] The present invention solves the above technical problems through the following technical solutions, which include an image acquisition module, a length detection module, an inner and outer arc surface detection module, a width detection module and a background management module;

[0008] The image acquisition module is used to acquire overhead images of the refractory bricks on the positioning frame and pre-process the images;

[0009] The length detection module is used to obtain the length characterization parameter of the current refractory brick based on the recognition result of the pre-processed refractory brick overhead image;

[0010] The inner and outer cambered surface detection module is used to obtain the inner and outer cambered surface accuracy characterization parameters of the current refractory brick based on the recognition result of the pre-processed refractory brick overhead image;

[0011] The width detection module is used to obtain the width characterization parameters of the current refractory brick based on the intermediate parameters obtained by the inner and outer arc surface detection modules;

[0012] The background management module is used to determine whether the length, inner and outer arc surface accuracy, and width of each refractory brick are within the error range based on the length characterization parameters, inner and outer arc surface accuracy characterization parameters, and width characterization parameters of each refractory brick, and record the number of qualified and unqualified refractory bricks and feed back to the brick forming control department.

[0013] Furthermore, the image acquisition module includes an image shooting unit and an image preprocessing unit; the image shooting unit is used to shoot vertically downward above the refractory bricks through an industrial camera to obtain an overhead image of the refractory bricks; the image preprocessing unit is used to perform noise reduction processing on the overhead image of the refractory bricks.

[0014] Furthermore, the positioning frame includes a first connecting plate, a second connecting plate, a boss, a recessed platform, a positioning circular plate and a connecting arm; wherein the first connecting plate and the second connecting plate are symmetrically arranged, and the positioning circular plate is respectively connected to the first connecting plate and the second connecting plate through two symmetrically arranged connecting arms, and the center of the positioning circular plate is located on the symmetry axis between the first connecting plate and the second connecting plate, the boss is arranged on the inner side of the first connecting plate, and the recessed platform is arranged on the inner side of the second connecting plate, and a positioning convex arc surface is provided on the boss, which matches the shape of the concave arc surface at the end of the standard refractory brick, and a positioning concave arc surface is provided on the recessed platform, which matches the shape of the convex arc surface at the end of the standard refractory brick; the gap between the positioning convex arc surface and the positioning concave arc surface can just accommodate a standard refractory brick; when the standard refractory brick is placed between the positioning convex arc surface and the positioning concave arc surface, the center position corresponding to the contour lines of the outer convex arc surface and the inner concave arc surface of the standard refractory brick coincides with the center point position of the positioning circular plate; standard refractory bricks refer to refractory bricks whose outer dimensions have no error with the designed outer dimensions.

[0015] Furthermore, the length detection module includes a first arc surface recognition unit, a second arc surface recognition unit and a length characterization parameter acquisition unit; the first arc surface recognition unit is used to detect and identify the first arc surface in the overhead image of the refractory brick using a trained target detection model, and obtain two first arc surface detection frame position information; the second arc surface recognition unit is used to detect and identify the second arc surface in the overhead image of the refractory brick using the target detection model, and obtain two second arc surface detection frame position information; the length characterization parameter acquisition unit is used to obtain the length characterization parameters of the current refractory brick based on the first arc surface detection frame position information and the second arc surface detection frame position information.

[0016] Furthermore, the specific processing process of the length characterization parameter acquisition unit is as follows:

[0017] Step S11: Obtaining the position information of two first arc surface detection frames and the second arc surface detection frame, wherein the first arc surface is the positioning convex arc surface and the concave arc surface of the end of the refractory brick, and the second arc surface is the positioning concave arc surface and the convex arc surface of the end of the refractory brick. The position information is the coordinates of the upper left corner point and the lower right corner point of the corresponding detection frame in the image;

[0018] Step S12: Calculating the center point coordinates of the two first arc surface detection frames based on the position information of the two first arc surface detection frames, and the center points of the two first arc surface detection frames are respectively recorded as M1 and M2; and simultaneously calculating the center point coordinates of the two second arc surface detection frames based on the position information of the two second arc surface detection frames, and the center points of the two second arc surface detection frames are respectively recorded as N1 and N2;

[0019] Step S13: Calculate the lengths of line segments M1N1, M1N2, N2M2, and N1M2, and select the shortest length among them as the length characterization parameter of the current refractory brick, denoted as C.

[0020] Furthermore, the inner and outer arc surface detection module includes a positioning circular plate recognition unit, a refractory brick recognition unit and a arc surface accuracy characterization parameter acquisition unit; the positioning circular plate recognition unit is used to use the target detection model to identify the positioning circular plate in the overhead image of the refractory brick, and obtain the positioning circular plate detection frame position information; the refractory brick recognition unit is used to use the target detection model to identify the refractory bricks as a whole in the overhead image of the refractory brick, and obtain the refractory brick detection frame position information; the arc surface accuracy characterization parameter acquisition unit is used to obtain the inner and outer arc surface accuracy characterization parameters of the current refractory brick based on the positioning circular plate detection frame position information and the refractory brick detection frame position information.

[0021] Furthermore, the specific processing process of the arc surface accuracy characterization parameter acquisition unit is as follows:

[0022] Step S21: obtaining the position information of the positioning circular plate detection frame and the refractory brick detection frame, wherein the position information is the coordinates of the upper left corner point and the lower right corner point of the corresponding detection frame in the image;

[0023] Step S22: Calculate the coordinates of the center point of the positioning circular plate detection frame according to the position information of the positioning circular plate detection frame. The center point of the positioning circular plate detection frame is recorded as Y, and its coordinates are used as the center point position of the positioning circular plate.

[0024] Step S23: cutting out the refractory brick detection frame area from the refractory brick overhead image according to the refractory brick detection frame position information, and recording it as the refractory brick detection frame area image;

[0025] Step S24: using the contour detection function in OpenCV to identify each contour line in the refractory brick detection frame area image, deleting the contour lines with a number of pixels less than a set threshold, and leaving two contour lines, namely the contour lines of the outer convex arc surface and the inner concave arc surface, which are recorded as the outer convex arc surface contour line L1 and the inner concave arc surface contour line L2;

[0026] Step S25: Read the coordinates of each pixel point on the outer convex arc contour line L1 and the inner concave arc contour line L2 respectively, and record them as Z 1j , Z 2k , where j represents the total number of pixels on the outer convex arc contour line L1, and k represents the total number of pixels on the inner concave arc contour line L2;

[0027] Step S26: Calculate the distance between each pixel point on the outer convex arc contour line L1 and the center point Y of the positioning circular plate detection frame, and calculate the mean value of the distance, which is recorded as the distance mean d 1avg At the same time, the distance between each pixel point on the inner concave arc contour line L2 and the center point Y of the positioning circular plate detection frame is calculated, and the mean of the distance is calculated, which is recorded as the distance mean d 2avg ; Among them, d 1avg >d 2avg ;

[0028] Step S27: Calculate the distance mean d 1avg and the preset first distance threshold d 1预设 The difference between them is recorded as D c1 ; At the same time calculate the distance mean d 2avg and the preset second distance threshold d 2预设 The difference between them is recorded as D c2 Among them, D c1 That is, the current characterization parameter of the accuracy of the outer arc surface of refractory bricks, D c2 That is, the parameter that characterizes the accuracy of the inner arc surface of current refractory bricks.

[0029] Furthermore, the specific processing process of the width detection module is as follows:

[0030] Step S31: Obtain the distance mean d in step S26 1avg , distance mean d 2avg ;

[0031] Step S32: Calculate the distance mean d 1avg , distance mean d 2avg The difference between them is denoted as K d , which is the width characterization parameter of the current refractory brick.

[0032] Furthermore, the specific processing process of the background management module is as follows:

[0033] Step S41: comparing the length characterization parameter, inner and outer camber surface accuracy characterization parameter, and width characterization parameter of each refractory brick with the preset refractory brick length characterization parameter threshold, inner and outer camber surface accuracy characterization parameter threshold, and width characterization parameter threshold respectively;

[0034] Step S42: For a single refractory brick, when all the characterization parameters are within the corresponding threshold range, it is considered a qualified product; when any characterization parameter is not within the corresponding threshold range, it is considered a failed product;

[0035] Step S43: Count and record the number of qualified and unqualified refractory bricks in the current batch, as well as the reasons for the unqualified products, and feed the data back to the brick forming control department.

[0036] Compared with the prior art, the present invention has the following advantages: the intelligent monitoring system for geopolymer production can accurately obtain the length characterization parameters, inner and outer arc surface accuracy characterization parameters, and width characterization parameters of refractory bricks; using the length between the center points of the corresponding detection frames as the length characterization parameter of the refractory brick, it can accurately and conveniently judge whether the length of the refractory brick is within the error range; and through the setting of the positioning circular plate in combination with the image recognition technology, it can accurately detect the inner and outer arc surface accuracy characterization parameters of the current refractory brick, and then accurately and conveniently judge whether the inner and outer arc surface accuracy of the refractory brick is within the error range; it also cleverly obtains the width characterization parameters of the current refractory brick based on the intermediate parameters obtained by the inner and outer arc surface detection module, and then accurately and conveniently judges whether the width of the refractory brick is within the error range. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 2. This is a schematic structural diagram of an arc-shaped geopolymer refractory brick according to an embodiment of the present invention (top view);

[0038] Figure 22. This is a schematic diagram of the overall structure of the arc-shaped geopolymer refractory brick according to an embodiment of the present invention (front view);

[0039] Figure 3 is a schematic block diagram of the structure of an intelligent monitoring system for geopolymer production according to an embodiment of the present invention;

[0040] Figure 4 Schematic diagram of the position of the arc-shaped geopolymer refractory brick when placed on the positioning frame in an embodiment of the present invention (top view);

[0041] Figure 5 Schematic diagram of an overhead image of refractory bricks in an embodiment of the present invention.

[0042] In the figure: 1, outer convex arc surface of outer contour; 2, inner concave arc surface of inner contour; 3, inner concave arc surface of end portion; 4, outer convex arc surface of end portion; 5, positioning slot; 6, positioning plug; 7, first connecting plate; 71, boss; 72, positioning outer convex arc surface; 8, second connecting plate; 81, concave boss; 82, positioning inner concave arc surface; 9, positioning circular plate; 10, connecting arm. DETAILED DESCRIPTION

[0043] The following is a detailed description of an embodiment of the present invention. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process. However, the protection scope of the present invention is not limited to the following embodiment.

[0044] like Figure 1 、 2 The figure shows a curved geopolymer refractory brick used in high-temperature furnace masonry construction in this embodiment. Its outer side has an outer convex curved surface 1, its inner side has an inner concave curved surface 2, one end has an inner concave curved surface 3, and the other end has an outer convex curved surface 4. Both the top and bottom surfaces are flat, with a square positioning slot 5 of a set depth reserved on the top surface, and a positioning block 6 of a set length on the bottom surface, matching the shape of the positioning slot 5. During masonry, the inner concave curved surface 3 and the outer convex curved surface 4 of two adjacent refractory bricks are connected end to end, forming a cylindrical furnace structure. The positioning slot 5 and the positioning block 6 cooperate to position the upper and lower layers of refractory bricks.

[0045] like Figure 3 、 4 As shown, this embodiment provides a technical solution: an intelligent monitoring system for geopolymer production, mainly used in the quality inspection link of the geopolymer refractory brick production process, including an image acquisition module, a length detection module, an inner and outer arc surface detection module, a width detection module and a background management module;

[0046] In this embodiment, the image acquisition module is used to acquire an overhead image of the refractory bricks on the positioning frame and pre-process the image.

[0047] As more specific, the image acquisition module includes an image capturing unit and an image preprocessing unit; the image capturing unit is used to capture an overhead image of the refractory bricks by an industrial camera vertically downwards. Figure 5 ; The image preprocessing unit is used to perform noise reduction on the overhead image of refractory bricks to improve the image quality.

[0048] It should be noted that during the inspection, a single refractory brick is placed on the positioning frame by manual or robot grasping, and the positioning frame includes a first connecting plate 7, a second connecting plate 8, a boss 71, a recessed platform 81, a positioning circular plate 9 and a connecting arm 10; wherein the first connecting plate 7 and the second connecting plate 8 are symmetrically arranged, and the positioning circular plate 9 is connected to the first connecting plate 7 and the second connecting plate 8 respectively through two symmetrically arranged connecting arms 10, and the center of the positioning circular plate 9 is located on the symmetry axis between the first connecting plate 7 and the second connecting plate 8, the boss 71 is arranged on the inner side of the first connecting plate 7, the recessed platform 81 is arranged on the inner side of the second connecting plate 8, and the boss 71 is provided with a positioning outer The convex arc surface 72 matches the shape of the inner concave arc surface 3 of the end portion, and a positioning inner concave arc surface 82 is provided on the concave platform 81, which matches the shape of the outer convex arc surface 4 of the end portion; the gap between the positioning outer convex arc surface 72 and the positioning inner concave arc surface 82 can just accommodate a standard refractory brick; the bottom surfaces of the convex platform 71 and the concave platform 81 are provided with corresponding supporting plates for supporting a single refractory brick placed between the positioning outer convex arc surface 72 and the positioning inner concave arc surface 82; when the standard refractory brick is placed between the positioning outer convex arc surface 72 and the positioning inner concave arc surface 82, the center position corresponding to the contour line of the outer convex arc surface 1 and the inner concave arc surface 2 of the standard refractory brick coincides with the center point position of the positioning circular plate 9.

[0049] It should be noted that standard refractory bricks refer to refractory bricks whose external dimensions have no error with the designed external dimensions.

[0050] In this embodiment, the length detection module is used to obtain the length characterization parameter of the current refractory brick according to the recognition result of the preprocessed overhead image of the refractory brick.

[0051] To be more specific, the length detection module includes a first arc surface recognition unit, a second arc surface recognition unit and a length characterization parameter acquisition unit; the first arc surface recognition unit is used to detect and identify the first arc surface in the overhead image of the refractory brick using a trained target detection model, and obtain two first arc surface detection frame position information; the second arc surface recognition unit is used to detect and identify the second arc surface in the overhead image of the refractory brick using the target detection model, and obtain two second arc surface detection frame position information; the length characterization parameter acquisition unit is used to obtain the length characterization parameters of the current refractory brick based on the first arc surface detection frame position information and the second arc surface detection frame position information.

[0052] It should be noted that the target detection model in this embodiment is trained based on the yolo v3s detection network and can achieve multi-target detection and classification.

[0053] More specifically, the specific processing process of the length characterization parameter acquisition unit is as follows:

[0054] Step S11: Obtaining the position information of two first arc surface detection frames and the position information of the second arc surface detection frame, wherein the first arc surface is the positioning convex arc surface 72 and the end concave arc surface 3, and the second arc surface is the positioning concave arc surface 82 and the end convex arc surface 4. The position information is the coordinates of the upper left corner point and the lower right corner point of the corresponding detection frame in the image;

[0055] Step S12: Calculating the center point coordinates of the two first arc surface detection frames based on the position information of the two first arc surface detection frames, and the center points of the two first arc surface detection frames are respectively recorded as M1 and M2; and simultaneously calculating the center point coordinates of the two second arc surface detection frames based on the position information of the two second arc surface detection frames, and the center points of the two second arc surface detection frames are respectively recorded as N1 and N2;

[0056] Step S13: Calculate the lengths of line segments M1N1, M1N2, N2M2, and N1M2, and select the shortest length among them as the length characterization parameter of the current refractory brick, denoted as C.

[0057] In the present invention, by calculating the detection frame position corresponding to the positioning of the convex arc surface 72 and the end concave arc surface 3, and calculating the detection frame position corresponding to the positioning of the concave arc surface 82 and the end convex arc surface 4, the length between the corresponding detection frame center points is used as the length characterization parameter of the refractory brick, which can accurately and conveniently determine whether the length of the refractory brick is within the error range.

[0058] In this embodiment, the inner and outer curved surface detection module is used to obtain the inner and outer curved surface accuracy characterization parameters of the current refractory brick based on the recognition result of the pre-processed overhead image of the refractory brick.

[0059] To be more specific, the inner and outer arc surface detection module includes a positioning circular plate recognition unit, a refractory brick recognition unit and a arc surface accuracy characterization parameter acquisition unit; the positioning circular plate recognition unit is used to use the target detection model to identify the positioning circular plate 9 in the overhead image of the refractory brick, and obtain the positioning circular plate detection frame position information; the refractory brick recognition unit is used to use the target detection model to identify the refractory bricks as a whole in the overhead image of the refractory brick, and obtain the refractory brick detection frame position information; the arc surface accuracy characterization parameter acquisition unit is used to obtain the inner and outer arc surface accuracy characterization parameters of the current refractory brick based on the positioning circular plate detection frame position information and the refractory brick detection frame position information.

[0060] More specifically, the specific processing process of the arc surface accuracy characterization parameter acquisition unit is as follows:

[0061] Step S21: obtaining the position information of the positioning circular plate detection frame and the refractory brick detection frame, wherein the position information is the coordinates of the upper left corner point and the lower right corner point of the corresponding detection frame in the image;

[0062] Step S22: Calculate the coordinates of the center point of the positioning circular plate detection frame according to the position information of the positioning circular plate detection frame. The center point of the positioning circular plate detection frame is recorded as Y, and its coordinates are used as the center point position of the positioning circular plate 9;

[0063] Step S23: cutting out the refractory brick detection frame area from the refractory brick overhead image according to the refractory brick detection frame position information, and recording it as the refractory brick detection frame area image;

[0064] Step S24: using the contour detection function in OpenCV to identify each contour line in the refractory brick detection frame area image, deleting the contour lines with a number of pixels less than a set threshold, and leaving two contour lines, namely the contour lines of the outer contour convex arc surface 1 and the inner contour concave arc surface 2, which are recorded as the outer contour convex arc surface contour line L1 and the inner contour concave arc surface contour line L2;

[0065] Step S25: Read the coordinates of each pixel point on the outer convex arc contour line L1 and the inner concave arc contour line L2 respectively, and record them as Z 1j , Z 2k , where j represents the total number of pixels on the outer convex arc contour line L1, and k represents the total number of pixels on the inner concave arc contour line L2;

[0066] Step S26: Calculate the distance between each pixel point on the outer convex arc contour line L1 and the center point Y of the positioning circular plate detection frame, and calculate the mean value of the distance, which is recorded as the distance mean d 1avg At the same time, the distance between each pixel point on the inner concave arc contour line L2 and the center point Y of the positioning circular plate detection frame is calculated, and the mean of the distance is calculated, which is recorded as the distance mean d 2avg ; Among them, d 1avg >d 2avg ;

[0067] Step S27: Calculate the distance mean d 1avg and the preset first distance threshold d 1预设 The difference between them is recorded as D c1 ; At the same time calculate the distance mean d 2avg and the preset second distance threshold d 2预设 The difference between them is recorded as D c2 Among them, D c1 That is, the current characterization parameter of the accuracy of the outer arc surface of refractory bricks, Dc2 That is, the parameter that characterizes the accuracy of the inner arc surface of current refractory bricks.

[0068] In the present invention, by setting a positioning circular plate in conjunction with image recognition technology, the accuracy characterization parameters of the inner and outer arc surfaces of the current refractory bricks can be accurately detected, and then it can be accurately and conveniently judged whether the accuracy of the inner and outer arc surfaces of the refractory bricks is within the error range.

[0069] In this embodiment, the width detection module is used to obtain the width characterization parameters of the current refractory brick according to the intermediate parameters obtained by the inner and outer arc surface detection module.

[0070] More specifically, the specific processing process of the width detection module is as follows:

[0071] Step S31: Obtain the distance mean d in step S26 1avg , distance mean d 2avg ;

[0072] Step S32: Calculate the distance mean d 1avg , distance mean d 2avg The difference between them is denoted as K d , which is the width characterization parameter of the current refractory brick.

[0073] In the present invention, the width characterization parameters of the current refractory brick are cleverly obtained based on the intermediate parameters obtained by the inner and outer arc surface detection modules, so that it can be accurately and conveniently judged whether the width of the refractory brick is within the error range.

[0074] In this embodiment, the background management module is used to determine whether the length, inner and outer arc surface accuracy, and width of the refractory bricks are within the error range based on the length characterization parameters, inner and outer arc surface accuracy characterization parameters, and width characterization parameters of each refractory brick, and record the number of qualified and unqualified refractory bricks, and feed back to the brick forming control department.

[0075] More specifically, the specific processing process of the background management module is as follows:

[0076] Step S41: comparing the length characterization parameter, inner and outer camber surface accuracy characterization parameter, and width characterization parameter of each refractory brick with the preset refractory brick length characterization parameter threshold, inner and outer camber surface accuracy characterization parameter threshold, and width characterization parameter threshold respectively;

[0077] Step S42: For a single refractory brick, when all the characterization parameters are within the corresponding threshold range, it is considered a qualified product; when any characterization parameter is not within the corresponding threshold range, it is considered a failed product;

[0078] Step S43: Count and record the number of qualified and unqualified refractory bricks in the current batch, as well as the reasons for the unqualified products, and feed the data back to the brick forming control department.

[0079] In the present invention, after the feedback is sent to the brick forming control department, the corresponding links in the brick forming process are adjusted according to the reasons for the failure of the unqualified products, thereby improving the brick qualification rate.

[0080] It should be noted that the thickness of bricks can be detected manually.

[0081] To sum up, the intelligent supervision system for geopolymer production of the above embodiment can realize the accurate acquisition of the length characterization parameters, inner and outer arc surface accuracy characterization parameters, and width characterization parameters of refractory bricks; using the length between the center points of the corresponding detection frames as the length characterization parameter of the refractory brick, it can accurately and conveniently judge whether the length of the refractory brick is within the error range; and through the setting of the positioning circular plate in combination with the image recognition technology, it can accurately detect the inner and outer arc surface accuracy characterization parameters of the current refractory brick, and then accurately and conveniently judge whether the inner and outer arc surface accuracy of the refractory brick is within the error range; it also cleverly obtains the width characterization parameters of the current refractory brick based on the intermediate parameters obtained by the inner and outer arc surface detection module, and then accurately and conveniently judges whether the width of the refractory brick is within the error range.

[0082] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0083] In the description of this specification, the reference terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and features of different embodiments or examples without contradiction.

[0084] Although the embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are illustrative and are not to be construed as limitations on the present invention. A person skilled in the art may change, modify, replace and modify the above embodiments within the scope of the present invention.

Claims

1. An intelligent monitoring system for geopolymer production, characterized in that: include: Image acquisition module, length detection module, inner and outer arc surface detection module, width detection module and background management module; The image acquisition module is used to acquire overhead images of the refractory bricks on the positioning frame and pre-process the images; The positioning frame includes a first connecting plate, a second connecting plate, a boss, a concave boss, a positioning circular plate and a connecting arm; wherein the first connecting plate and the second connecting plate are symmetrically arranged, and the positioning circular plate is respectively connected to the first connecting plate and the second connecting plate through two symmetrically arranged connecting arms, and the center of the positioning circular plate is located on the symmetry axis between the first connecting plate and the second connecting plate, the boss is arranged on the inner side of the first connecting plate, and the concave boss is arranged on the inner side of the second connecting plate, and a positioning outer convex arc surface is provided on the boss, which matches the shape of the inner concave arc surface of the end of the standard refractory brick, and a positioning inner concave arc surface is provided on the concave boss, which matches the shape of the outer convex arc surface of the end of the standard refractory brick; the gap between the positioning outer convex arc surface and the positioning inner concave arc surface can just accommodate a standard refractory brick; when the standard refractory brick is placed between the positioning outer convex arc surface and the positioning inner concave arc surface, the center position corresponding to the contour line of the outer convex arc surface and the inner concave arc surface of the standard refractory brick coincides with the center point position of the positioning circular plate; standard refractory bricks refer to refractory bricks whose outer dimensions have no error with the designed outer dimensions; The length detection module is used to obtain the length characterization parameter of the current refractory brick based on the recognition result of the pre-processed refractory brick overhead image; The inner and outer cambered surface detection module is used to obtain the inner and outer cambered surface accuracy characterization parameters of the current refractory brick based on the recognition result of the pre-processed refractory brick overhead image; The width detection module is used to obtain the width characterization parameters of the current refractory brick based on the intermediate parameters obtained by the inner and outer arc surface detection modules; The background management module is used to determine whether the length, inner and outer arc surface accuracy, and width of each refractory brick are within the error range based on the length characterization parameters, inner and outer arc surface accuracy characterization parameters, and width characterization parameters of each refractory brick, and record the number of qualified and unqualified refractory bricks and feed back to the brick forming control department.

2. The intelligent monitoring system for geopolymer production according to claim 1, characterized in that: The image acquisition module includes an image capturing unit and an image preprocessing unit; the image capturing unit is used to capture vertically downward images of the refractory bricks through an industrial camera; the image preprocessing unit is used to perform noise reduction processing on the overhead images of the refractory bricks.

3. The intelligent monitoring system for geopolymer production according to claim 2, characterized in that: The length detection module includes a first arc surface recognition unit, a second arc surface recognition unit and a length characterization parameter acquisition unit; the first arc surface recognition unit is used to detect and recognize the first arc surface in the overhead image of the refractory brick using a trained target detection model, and obtain position information of two first arc surface detection frames; The second arc surface recognition unit is used to detect and identify the second arc surface in the overhead image of the refractory brick using the target detection model, and obtain the position information of two second arc surface detection frames; the length representation parameter acquisition unit is used to obtain the length representation parameter of the current refractory brick based on the first arc surface detection frame position information and the second arc surface detection frame position information.

4. The intelligent monitoring system for geopolymer production according to claim 3, characterized in that: The specific processing process of the length characterization parameter acquisition unit is as follows: Step S11: Obtaining the position information of two first arc surface detection frames and the second arc surface detection frame, wherein the first arc surface is the positioning convex arc surface and the concave arc surface of the end of the refractory brick, and the second arc surface is the positioning concave arc surface and the convex arc surface of the end of the refractory brick. The position information is the coordinates of the upper left corner point and the lower right corner point of the corresponding detection frame in the image; Step S12: Calculating the center point coordinates of the two first arc surface detection frames based on the position information of the two first arc surface detection frames, and the center points of the two first arc surface detection frames are respectively recorded as M1 and M2; and simultaneously calculating the center point coordinates of the two second arc surface detection frames based on the position information of the two second arc surface detection frames, and the center points of the two second arc surface detection frames are respectively recorded as N1 and N2; Step S13: Calculate the lengths of line segments M1N1, M1N2, N2M2, and N1M2, and select the shortest length among them as the length characterization parameter of the current refractory brick, denoted as C.

5. The intelligent monitoring system for geopolymer production according to claim 4, characterized in that: The inner and outer arc surface detection module includes a positioning circular plate recognition unit, a refractory brick recognition unit and a arc surface accuracy characterization parameter acquisition unit; the positioning circular plate recognition unit is used to use the target detection model to identify the positioning circular plate in the overhead image of the refractory brick, and obtain the positioning circular plate detection frame position information; the refractory brick recognition unit is used to use the target detection model to identify the refractory bricks as a whole in the overhead image of the refractory brick, and obtain the refractory brick detection frame position information; the arc surface accuracy characterization parameter acquisition unit is used to obtain the inner and outer arc surface accuracy characterization parameters of the current refractory brick based on the positioning circular plate detection frame position information and the refractory brick detection frame position information.

6. The intelligent monitoring system for geopolymer production according to claim 5, characterized in that: The specific processing process of the arc surface accuracy characterization parameter acquisition unit is as follows: Step S21: obtaining the position information of the positioning circular plate detection frame and the refractory brick detection frame, wherein the position information is the coordinates of the upper left corner point and the lower right corner point of the corresponding detection frame in the image; Step S22: Calculate the coordinates of the center point of the positioning circular plate detection frame according to the position information of the positioning circular plate detection frame. The center point of the positioning circular plate detection frame is recorded as Y, and its coordinates are used as the center point position of the positioning circular plate. Step S23: cutting out the refractory brick detection frame area from the refractory brick overhead image according to the refractory brick detection frame position information, and recording it as the refractory brick detection frame area image; Step S24: using the contour detection function in OpenCV to identify each contour line in the refractory brick detection frame area image, deleting the contour lines with a number of pixels less than a set threshold, and leaving two contour lines, namely the contour lines of the outer convex arc surface and the inner concave arc surface, which are recorded as the outer convex arc surface contour line L1 and the inner concave arc surface contour line L2; Step S25: Read the coordinates of each pixel point on the outer convex arc contour line L1 and the inner concave arc contour line L2 respectively, and record them as Z 1j , Z 2k , where j represents the total number of pixels on the outer convex arc contour line L1, and k represents the total number of pixels on the inner concave arc contour line L2; Step S26: Calculate the distance between each pixel point on the outer convex arc contour line L1 and the center point Y of the positioning circular plate detection frame, and calculate the mean value of the distance, which is recorded as the distance mean d 1avg At the same time, the distance between each pixel point on the inner concave arc contour line L2 and the center point Y of the positioning circular plate detection frame is calculated, and the mean of the distance is calculated, which is recorded as the distance mean d 2avg ; Among them, d 1avg >d 2avg ; Step S27: Calculate the distance mean d 1avg and the preset first distance threshold d 1预设 The difference between them is recorded as D c1 ; At the same time calculate the distance mean d 2avg and the preset second distance threshold d 2预设 The difference between them is recorded as D c2 Among them, D c1 That is, the current characterization parameter of the accuracy of the outer arc surface of refractory bricks, D c2 That is, the parameter that characterizes the accuracy of the inner arc surface of current refractory bricks.

7. The intelligent monitoring system for geopolymer production according to claim 6, characterized in that: The specific processing process of the width detection module is as follows: Step S31: Obtain the distance mean d in step S26 1avg , distance mean d 2avg ; Step S32: Calculate the distance mean d 1avg , distance mean d 2avg The difference between them is denoted as K d , which is the width characterization parameter of the current refractory brick.

8. The intelligent monitoring system for geopolymer production according to claim 1, characterized in that: The specific processing process of the background management module is as follows: Step S41: comparing the length characterization parameter, inner and outer camber surface accuracy characterization parameter, and width characterization parameter of each refractory brick with the preset refractory brick length characterization parameter threshold, inner and outer camber surface accuracy characterization parameter threshold, and width characterization parameter threshold respectively; Step S42: For a single refractory brick, when all the characterization parameters are within the corresponding threshold range, it is considered a qualified product; when any characterization parameter is not within the corresponding threshold range, it is considered a failed product; Step S43: Count and record the number of qualified and unqualified refractory bricks in the current batch, as well as the reasons for the unqualified products, and feed back the number of qualified and unqualified products and the reasons for the unqualified products to the brick forming control department.

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